Manitou MT 1135 EASY 75D ST5 S1 to MT 1335 HA EASY 75D ST5 S1 Repair Manual 647802EN

Description

• Model List:
  • MT 1135 EASY 75D ST5 S1
  • MT 1135 H EASY 75D ST5 S1
  • MT 1135 HA EASY 75D ST5 S1
  • MT 1335 EASY 75D ST5 S1
  • MT 1335 H EASY 75D ST5 S1
  • MT 1335 HA EASY 75D ST5 S1

• 1. Page de garde / Front page
• 2. Sommaire général General table of content
• 4. GENERAL, CHARACTERISTICS AND SAFETY
• 4.1. Work during the Warranty Period
• 4.2. GENERAL INSTRUCTIONS AND SAFETY NOTICE
• 4.2.1. FOREWORD
• 4.2.2. SERVICING POSITION
• 4.2.3. EXPLANATION OF SYMBOLS
• 4.2.4. SERVICING RULES
• 4.3. GENERAL CHARACTERISTICS AND SPECIFICATIONS
• 4.3.1. CHARACTERISTICS
• 4.3.2. LUBRICANTS AND FUEL
• 4.3.3. DIMENSIONS
• 4.4. GENERAL LOCATION
• 4.4.1. LOCATION OF NAME AND IDENTIFICATION PLATE
• 4.5. GENERAL CONTROL AND ADJUSTMENT
• 4.5.1. STANDARD TIGHTENING TORQUES
• 4.5.2. METRIC IMPERIAL UNIT CONVERSION
• 6. ENGINES
• 6.1. CHARACTERISTICS AND SPECIFICATIONS
• 6.1.1. CHARACTERISTICS
• 6.2. Engine Schematic Diagrams
• 6.2.1. Intake circuit and EGR
• 6.2.2. Lubrication circuit
• 6.2.3. Cooling circuit
• 6.2.4. Fuel circuit
• 6.3. Location
• 6.3.1. Engine
• 6.3.2. Water cooling system
• 6.3.3. Diesel fuel circuit
• 6.3.4. Fuel injection circuit
• 6.3.5. EGR circuit
• 6.4. Control and adjustment
• 6.4.1. Diesel fuel circuit tightening torques
• 6.4.2. Exhaust circuit tightening torques
• 6.4.3. Heating system tightening torques
• 6.5. Removal Refit
• 6.5.1. PREPARATION AND SAFETY INSTRUCTIONS
• 6.5.2. Removing the engine cover
• 6.5.3. Removing the starter motor
• 6.5.4. Removing the belt casing
• 6.5.5. Removing the attachment belt
• 6.5.6. Removing THE AIR CONDITIONING BELT
• 6.5.7. Remove the alternator
• 6.5.8. Removing the water pump
• 6.5.9. Removing the fuel filter
• 6.5.10. Remove the engine ECU
• 6.5.11. Removing the AIR CONDITIONING COMPRESSOR
• 6.5.12. Removing the exhaust line
• 6.5.13. Removing the turbo
• 6.5.14. Remove the expansion tank
• 6.5.15. Removing the radiator
• 6.5.16. Removing the hydraulic enginefan assembly
• 6.5.17. REMOVING THE FUEL TANK
• 6.5.18. Removing the engine
• 6.6. TROUBLESHOOTING
• 6.6.1. ENGINE ERROR CODES
• 6.6.2. IGNITION SWITCHING TEST
• 6.6.3. STARTUP CONDITIONS
• 6.6.4. LACK OF POWER
• 6.6.5. Error table
• 6.7. SPECIFIC TOOLING
• 6.7.1. Special engine tooling
• 6.7.2. ELECTRONIC TENSION METER
• 8. TRANSMISSION
• 8.1. Schematic diagrams
• 8.1.1. MECHANICAL TRANSMISSION
• 8.1.2. HYDROSTATIC TRANSMISSION
• 8.2. Location
• 8.2.1. MECHANICAL GEARBOX PORTS
• 8.2.2. HYDROSTATIC TRANSMISSION
• 8.3. Control and adjustment
• 8.3.1. General authorisation conditions for carriage movement
• 8.3.2. Verification of hydrostatic carriage configurations
• 8.3.3. Eco Mode on hydrostatic carriages
• 8.3.4. TIGHTENING TORQUES
• 8.3.5. MECHANICAL TRANSMISSION PRESSURE TEST PORT values
• 8.3.6. H GEAR LOCKING
• 8.3.7. HYDROSTATIC TRANSMISSION PRESSURE TEST PORT values
• 8.4. REMOVAL
• 8.4.1. PREPARATION AND SAFETY INSTRUCTIONS
• 8.4.2. MECHANICAL GEARBOX REMOVAL
• 8.4.3. HYDROSTATIC TRANSMISSION REMOVAL
• 8.5. TROUBLESHOOTING
• 8.5.1. HYDROSTATIC SYSTEM
• 8.6. SPECIFIC TOOLING
• 8.6.1. BASIC MANOMETER BOX
• 8.6.2. DIGITAL MANOMETER BOX
• 8.6.3. HYDROMATIK KIT (Replacement A 4 VG DA pump/A 6 VM DA engine)
• 8.6.4. MM MACHINED SOCKET
• 10. BRAKE
• 10.1. CHARACTERISTICS AND SPECIFICATIONS
• 10.1.1. SERVICE BRAKE (MECHANICAL AND HYDROSTATIC)
• 10.1.2. PARKING BRAKE
• 10.2. CONTROL AND ADJUSTMENT
• 10.2.1. SERVICE BRAKE
• 10.2.2. PARKING BRAKE
• 10.2.3. FREEWHEEL AND TOWING
• 10.3. Removal
• 10.3.1. PREPARATION AND SAFETY INSTRUCTIONS
• 10.3.2. MASTER CYLINDER REMOVAL
• 10.3.3. PARKING BRAKE REMOVAL
• 10.4. SPECIFIC TOOLING
• 10.4.1. BRAKE FLUID BLEEDER
• 10.4.2. PARKING BRAKE BLEEDER HARNESS
• 12. BOOM
• 12.1. CHARACTERISTICS AND SPECIFICATIONS
• 12.1.1. TRIPLEX (MT 11/13 METRES)
• 12.2. Location
• 12.2.1. LOCATION OF MAIN TRIPLEX BOOM COMPONENTS
• 12.3. CONTROL AND ADJUSTMENT
• 12.3.1. TELESCOPE EXTENSION AND RETRACTION ADJUSTMENT PROCEDURE
• 12.3.2. RECOMMENDATION FOR FITTING SHIMS AND LUBRICATION AREAS
• 12.3.3. TIGHTENING TORQUE AND LUBRICATION AREA
• 12.4. REMOVAL Refit
• 12.4.1. PREPARATION AND SAFETY INSTRUCTIONS
• 12.4.2. COMPLETE BOOM REMOVAL
• 12.4.3. TELESCOPING CIRCUIT REMOVAL
• 12.4.4. REMOVAL OF TELESCOPES T1T2
• 12.4.5. COMPLETE BOOM REFIT
• 12.4.6. INTERMEDIATE TELESCOPE T1 REFIT
• 12.4.7. BOOM HEAD TELESCOPE T2 REFIT
• 12.4.8. TELESCOPING CIRCUIT REFIT
• 12.5. SPECIFIC TOOLING
• 12.5.1. PIPE END PIECES
• 12.5.2. MAGNETIC LIFTER
• 14. HYDRAULICS
• 14.1. Characteristics and specifications
• 14.1.1. Hydraulic sheets
• 14.2. SCHEMATIC DIAGRAMS
• 14.2.2. MT 1135 1335
• 14.2.3. MT 1135 1335 H
• 14.2.4. MT 1135 1335 HA
• 14.3. LOCATION
• 14.3.2. MT 1135 1335
• 14.3.3. MT 1135 H A / MT 1335 H A
• 14.4. CONTROL AND ADJUSTMENT
• 14.4.1. OPERATION OF COMPENSATING ISOLATION VALVES (VIC)
• 14.4.2. ACCUMULATION OF THE FLOW RATES OF THE ACCESS DISCHARGE VALVE
• 14.4.3. PRESSURE TEST PORTS
• 14.4.4. PROCEDURES FOR PURGING REAR AXLE LOCKING CYLINDERS
• 14.4.5. TIGHTENING TORQUES
• 14.4.6. COUNTERBALANCE VALVE TEST PROCEDURE (MT 1135/1335 HA)
• 14.4.7. TESTING THE LIFTING AND TILTING CYLINDER VALVES
• 14.4.8. TESTING THE TELESCOPE CYLINDER VALVES
• 14.4.9. TESTING THE STABILISER CYLINDER VALVES
• 14.4.10. TESTING THE LEVELLING CYLINDER VALVE
• 14.5. REMOVAL
• 14.5.1. PREPARATION AND SAFETY INSTRUCTIONS
• 14.5.2. REMOVING THE DISTRIBUTOR
• 14.5.3. HYDRAULIC PUMP REMOVAL
• 14.5.4. ACCUMULATOR UNIT REMOVAL
• 14.5.5. AXLE LOCKING CYLINDER REMOVAL
• 14.5.6. STABILISER CYLINDER REMOVAL
• 14.5.7. LEVELLING CYLINDER REMOVAL (MT 1135/1335 H A)
• 14.6. SPECIFIC TOOLING
• 14.6.1. BASIC MANOMETER BOX
• 14.6.2. DIGITAL MANOMETER BOX
• 16. ELECTRICITY
• 16.1. CHARACTERISTICS AND SPECIFICATIONS
• 16.1.1. FUSES AND RELAYS
• 16.1.2. ECU INPUTS/OUTPUTS
• 16.1.3. TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
• 16.2. SCHEMATIC DIAGRAMS
• 16.2.1. ELECTRICAL DIAGRAM CODIFICATION EXAMPLE
• 16.2.2. MARKING OF CABLES ON A WIRING HARNESS
• 16.2.3. MT 1135 1335
• 16.2.4. MT 1135 1335 H
• 16.2.5. MT 1135 1335 HA
• 16.3. LOCATIONS
• 16.3.1. MT 1135 1335
• 16.3.2. MT 1135 1335 H
• 16.3.3. MT 1135 1335 HA
• 16.4. CONTROL AND ADJUSTMENT
• 16.4.1. ADJUSTMENT OF INDUCTIVE SENSOR ON BOOM
• 16.4.2. Longitudinal stability limiter and warning device
• 16.4.3. BOOM ANGLE ANGULAR SENSOR ADJUSTMENT
• 16.5. Removal refit
• 16.5.1. REFITTING THE STRAIN GAUGE
• 16.5.2. Remove Replace JSM on BMEP
• 16.6. TROUBLESHOOTING
• 16.6.1. Engine ECU DTC
• 16.6.2. Harmony screen DTC
• 16.6.3. Main ECU DTC SPU 4026
• 16.6.4. Auxiliary ECU DTC SPU 2515 SPU 4026
• 16.7. SPECIFIC TOOLING
• 16.7.1. DIAGNOSTIC TOOLS
• 16.7.2. BREAKOUT BOXES
• 16.7.3. ELECTROVALVE ADAPTER
• 18. DRIVERS CAB
• 18.1. REMOVAL Refit
• 18.1.1. CAB LOWER TRIM REMOVAL
• 18.1.2. ELECTRIC WINDOW AND ENGINE REMOVAL
• 18.1.3. ELECTRIC WINDOW AND ENGINE REFIT
• 20. FRAME BODYWORK
• 20.1. CONTROL AND ADJUSTMENT
• 20.1.1. FUEL TANK AND OIL TANK STOP ADJUSTMENT
• 22. OPTIONS ATTACHMENTS
• 23. AIR CONDITIONING OPTION
• 23.1. Characteristics and specifications
• 23.1.1. Description of operation
• 23.1.2. Evaporator temperature sensor specifications
• 23.2. SCHEMATIC DIAGRAMS
• 23.3. Locations
• 23.3.1. Components AND TIGHTENING TORQUES
• 23.3.2. HVAC interior components
• 23.3.3. HVAC exterior components
• 23.3.4. Condenser components
• 23.4. Control and adjustment
• 23.4.1. General check points
• 23.4.2. Refrigerant fluid load
• 23.5. Removal refit
• 23.5.1. SAFETY MEASURES FOR HANDLING R134A
• 23.5.2. ASSEMBLY INSTRUCTION
• 23.5.3. AIR CONDITIONING BELT REMOVAL
• 23.5.4. AIR CONDITIONING BELT REFIT
• 23.5.5. Check the evaporator temperature sensor
• 23.6. Troubleshooting
• 23.6.1. Temperature Fault
• 23.6.2. Unusual noise
• 23.6.3. Unpleasant smell